Pile fabric and method of making the same



Jan. 13, 1942. H, H, BAYNTON 2,270,103

FILE FABRIC AND METHOD OF MAKING THE SAME Filed March 8, .1940 2 Sheets-She et 1 6 E: 4 :;i,:: 7 16 u 0 I. J 3 0 LL LL flarald )Zfiaymiam Jan. 13, 1942. H. H. BAYNTON FILE FABRIC AND METHOD OF MAKING THE SAME v Fild March a, 1940 2 Sheets-Sheet 2 P// 'a/%/f Patented Jan. 13, 1942 s PATENT OFFICE I I UNITED 1 STATE Harold H; Baynton, Freehold, N. J., assignorto .A. & M. Karagheusian lnc New York, N. Y., a v .cprporation ot-Delaware bossed effect This isfobtai'ned by "having certain yarn' ends woven in the back "or basefsfof that thereisno'jcut or uncutyarri in the' design or motif but ratherfjar'fabse'nce of," yarn; which makes the motif discernible from light'refraction at different angles.

A. further object of the inventionis'toprovide yarns and thelcut pile, which isthe'prdinary or cohvehnshaiwaym provide patterns br'motifs in pile fabricsg'enerally of one color; "and to further Ab Ii'cationQ-March a, 19510, Serial No; 23,013 a (o1. 1s'9,-,-4o6)- ,F' a I Referring now to the drawings showing a prefferred-embodiment,

I Fig. 1 is aitoppla'n'viewof apiece of pile fabric showing a primary motif, wherein the cut pile le s a pile fabric wherein the principal motif or the most discernible. motifwouldconsis't of 'the'uncut combine what might be termed a secondary motif, 7

which is apparent when viewed from different angles by the light refraction and which is caused ,byan absence of yarn or pile. However, the adjacent pile will fold .or be compressed, so that this ,secondary motif becomes very faint but nevertheless apparent.

Stillanother objectof theihvehnohistoprovid' apile fabric wherein the entire. fabric can be made heavy. and more compact because of the anduncut yarn form the flower and wherein the absence of-pile-yarnforms the outline of the I Fig. 2 is a fragmenta'ry diagrammatic view of the yarn being fed to the loom; t

Fig. 3 is a diagrammatic 'view showing the conventional courses with the yarn ends';'

,Figl i isa similar view showing my new art e ent: l

avi'ew oftheconventional weave of 'several'coursesfas seen'ir'o'm the rear;

@Fig". 6 shows'my new and improved weave when the coursesland -yarn are arranged as shown in gg4jand as also'vieWed-from the rear; and

tional view of y improved pile fabric, showing the cut'pile ,'uncut yarns, and the absence of yarns in the face of the fabric, and for the sim- Lplici'ty of illustration I have shown only five of the yarns rather thanten.

Referring now more particularly to the several lviewsg'it will be understood at the outset that the drawings are merely illustrative" of the "prevariation of yarn weights, which may be used to Y thereby present a heavier weight fabric having j longer wearing qualities, together with" a lush I pile alsocombiningthe embossedmotifas well as the less apparent motif, thus.gr'eatly "adding to the beauty of the rug or carpet.

Still another objectof the invention is'to proyarns may be used so that the pilefmay be formed of arns of one weight while the uncut. yarns will be of a different weightto thus provide the rug.

Still another object of the invention is to provide a ,fabric formed on a loom wherein each course is twice as heavy as has heretofore been the custom. so that an extremely heavy ribbed eifect may be noticed with the extra yarn ends firmly clamped together and held in place by the double chains and, stufiers.

With these and other objects. in view, the invention consists in certain new and novel features and combination of parts, as will be hereinafter more fully explained and pointed vout in the claims.

ferred 'form of'the invention andare diagrammaticin'theirfnature.

'. Lm'I'h'e 'dia'grarnmatio iew-of' theloom is to show howthe yarns of different weight may be utilized to form. the new fabricr Thefmechanical"change necessaryin"the standard loom-is to change the pitch, which is' 'accomplished by changing the reader comb, which is,"o f course, divided into a number of slits. Briefly stated, a'loom with a f two hundred and fifty six' (256) pitch has a reed duce a pile .fabric l wherein various weights of or comb comprised 0f1two hundred and fifty-six (256) slits, through each of which passes a th desired contrast as .well as serviceability to course Due to the" fact that different design units require difierentweights of yarn tomake them sharp and satisfactory, looms may be readily adjusted with reeds of slightly different pitch in order to provide sufficient space for the yarns, chains, and stuffer. ends which are to be drawn through them. t v I v In order to obtain the weave that I am about to illustrate, the loom is set up in such a Waythat the same loom will draw th equivalent of two hundred and fifty-six (256) courses through a reed having only one hundred and twenty-eight (128) slits. In other words, the samenumber of courses that are ordinarily used in a loom having a pitch of two hundred and fifty-six (256 are "f now arranged in the loom having a-pitth of only one hundred and twenty-eight (128) or half of what has been the usual practice.

Thus, in my new and improved weave, there will be passed through each course four chain ends, four (more or less) stuffer ends, and the equivalent in weight of four twenty-four (24) yard" yarn ends and six ,fifty (50) yard" yarn ends, distinguished from the conventional weaving of a course with two chain ends, two stuifer ends, and the equivalent of five yarn ends of fifty yarn weight in a three-quarter yard carpet loom having a two hundred and fifty-six (256) pitch.

It will be noted that these weights of yarns mentioned in my new method may be varied and are set out as exemplary of the manner in which the multiplicity of yarns of light and heavy weights may be run through half the number of reeds.

It is also to be noted that it is not necessary to double the number of yarns but it is desirable to invariably double the usual or customary total weight of yarns drawn through each course. It might further be desirable for an extremely soft motif to have, say, fifteen yarn ends as compared to ten. The comparison is in the total weight of all these yarn ends, stufiers, and chains rather than their number. Although it is.still further desirable to use a normal complement of twice the number of stuifers, it might be possible, due to the type of effect wished, to eliminate one of the stuffers and weave satisfactorily with only three, making up the weight thus saved in the absence of a stufier by the use of heavier yarns.

In other words, the total weight of yarns, stuffers, etc., of the new course is to be double that of the weight of the old course.

Referring now for the moment to Fig. 2, there is diagrammatically shown as much of the weaving portion-of a jacquard loom as is thought necessary to illustrate the invention.

Glancing at the figures for the moment, there may be seen the stuffer beam 1 and the chain beam 2 together with the lay sword 3 having the reed or comb 4, through which the various yarns pass to the spike roller 5, certain of the yarns being acted on, of course, by the pile. wire cutters 6, while others of the loops, as will be mentioned, are passed about th pile wires but are not out. The pile wires, of course, are situated above the breast plate I, as is the conventional method.

Also there may be seen the stuffer heddle B, the chain heddles 9 and I0, and the lingoes H, which latter, of course, are operated from the jacquard cards.

All of the above parts are conventional, with the exception of the reed or comb which, in this instance, instead of having a pitch of two hundred and fifty-six (256) has a pitch of one hundred and twenty-eight (128) and, in reality, two ordinary courses pass through each slit. The yarn ends are drawn from the frames (not shown) through the needle eyes I! in the lingoes, which are controlled by the jacquard cards (not shown). The raising of these lingoes, through which pass certain weights and types or colors of yarn, determines the color and type and design or motifs on the fabric when properly set up to cooperate with the pile wires, some of which are provided with cutters and some of which are not, so that the yarns may be looped about the latter but not cut on the withdrawal of the pile wires.

The stuffers l3 are drawn from the stuffer beam I while the chains are drawn from the chairiobeam 2 through their respective heddies l and The course comprised of the proper number of chains, stuffers, and yarn ends is lifted through the slits of the reed or comb 4, at which point the yarns become engaged with the nearest pile wire 6 and the customary crosswise shot yarn (not shown) is positioned. The lay sword 3 passing from left to right will force the weave tightly together and the yarn over the pile wires and up to the breast plate 1, after which the pile wires whip through, leaving the finished fabric that rolls forward with each successive action of the loom and which fabric passes over the spike roller 5 in the conventional manner.

In Fig. 3, there is schematically shown a cross section of part of a reed illustrating the composition or arrangement of eight typical or conventional courses within the eight slitsof a two hundred and fifty-six (256) pitch reed. As heretofore mentioned, there may also be seen the two chain ends C-E, two stuffer ends SE. and five yarn ends Y--E of approximately fifty yarn weight. This weave produces a carpet or fabric, as fragmentarily shown (rear) in Fig. 5. Here may be seen the chains or hinder chains C--E together, with the yarn Y and the stuffer yarns held by the weft thread shots S.

Now with a pile fabric made in the above manner, it is possible to produce a motif caused by the cut pile and the uncut yarn, which motif is controlled, of course, by the jacquard cards. However, it is impossible or impractical to use a Weave of this kind to also produce, besides the motif formed by the cut pile and the uncut yarn, a further secondary motif or part of the main motif by providing a pattern formed by absence of cut pile and yarn in the face of the fabric.

However, with the new weave and a doubling of the size of the course,- it is possible not only to form a motif with the cut pile and the uncut yarn, but I can also produce a subtle motif by an absence of yarn and its cut pile following a distinct pattern. Thus, for instance, a flower or petal may be formed with the cut pile and the uncut yarn, while the thin line or outline of a leaf may also be formed by an absence of the cut pile.

It will be understood that the pile adjacent the edges of the motif line will tend to spread or blossom and especially after being walked on, so that there is just a faint outline of the motif, which, however, is discernible when viewed from different angles, thus creating a very pleasing effect to the pile fabric.

Referring now to Figs. 4 and 6, and for the moment to Fig. 4, there is shown a portion of the comb or reed and in this instance, instead of having eight slits, it will be noticed that there are only four. It will also be noticed that in this instance, we have four chain ends C-E, four stuifer ends S--E, four twenty-four (24) yard yarn ends YE, and six fifty (50) yard yarn ends Y-E. These numbers are illustrative, as the weights may be varied.

Thus, in the new weave, the chains are doubled, the stuffer yarns are doubled, and the yarn ends are doubled, and also the heavier and lighter yarns may be used in the one course, so that the uncut yarn may be more apparent in the motif and additionally provide, of course, a heavier and longer-wearing carpet.

In Fig. 6 may be seen the binder chains C-E, and in this instance, there will be one above the .of light.

ribbed effect. as will be noticed in the design other and there may also be seen the yarns Y and the stufier yarns E. These yarns and stuffer yarns may be intermingled in any desired manner and are held by the conventional weft shots S. The six fifty (50) yard" yarn ends and the four twenty-four (24) yard" yarn ends may be varled to suitthe desired motif. Thus, it will be seen that in the one course,'I have doubled the yarn, chains, and stuifers.

By having this number of yarn ends, chains, and stuffers in the one course, it is possible to form the motif of cut and uncut yarns, which latter, being relatively heavy yarns, stand out more distinctly and provide agreater contrast to the eye, as may be seen in Fig. 1. These uncut yarns, of course, are yarns that are passed over the pile wires, but the pile wires being devoid of spoon and cutter blades withdraw, leaving uncut loops.

It might also be mentioned in passing that the pile wires, about which these uncut loops are passed, may be of different sizes, widths, or height 'to accommodate the coarser or heavier yarn and to'provide longer loops for the pile.

Furthermore. it is thus possible to provide a subtle pattern by running certain of the yarns into the base of the carpet and thus leave a slight space between the cut pile.

In Fig. 7, I have illustrated the cut pile, as may be seen at P, the uncut yarn. as 'may be seen at p, and an absence of raised yarn and, therefore. absence of pile, as at H. Here the yarn has been left unraised from the face of the carpet and bound down into the base to thus provide a space forming a pattern running through, the pile. The cut pile, however, adjacent the portion l4 tends to spread orblossom.

so that the motif formed by the absence of raised I yarn ends (the yarn here being bound into the base) produces a design that is not as readily apparent'as the cut and uncut pile but, nevertheless, may be clearly seen by different r efractions It will be noticed that for the simplicity of illustration, I have shown only five yarn ends Y-E rather than ten.

Thus, it is possible to weave in the one piece the back Or base of the carpet rather than pulled V of pile fabric a combination of the pile tufts and:

uncut pile yarn to form one part of the motif and to provide a second part or secondary motif inthe same fabric by an absence of pile yarn in the face of the pile fabric. A further motif of raised or embossed effect can also be obtained through the use of wider pile wires. properly positioned.

It is necessary to have a course with the multiple chains and stuffers and yarns, all as abovedescribed, in the weave to make possible these motifs caused by the two methods above-outlined.

It will also be understood that it would not be possible to force all these yarns, chains, and stul'lers of one course into the respective number of the slits, as shown in Fig. 3, and if they were admitted, the material would be so tight that the lingoes could not raise the required ends without tearing or breaking them.

It also follows that if the courses of the customary sized number were used. as shown in Fig. 1, and drawn through this reed with a reduced number of slits. the pile would be so scant that there would be virtually no design whatever in the fabric.

Each course being twice as heavy and provided with yarns of relatively heavy weight bound in with double chain ends produce a very heavy shown in Fig. 1. Thus, there is provided on the face of the fabric, where the woven loops of yarn are cut. an exceptionally heavy and luxuriant blossoming or spreading of the pile from the tightly bound yarns.

Also the entire fabric can be made heavier and more compact because the yarn weights may be varied, and it is possible to provide for out and uncut yarns and further to provide an absence of yarn to form what might be termed a carved effect (the absent yarn ends disappearing at up by lingoes to the face of the fabric), an embossed effect being obtained through the cut pile and the-proper positioning of pile wires of relatively greater width and height than otherwise used.

From the,foregoing, it will be seen that by changing the comb or reed, I, can double the number of chains. stuffers. and yarns in each course and vary the weights of the yarns to produce different effects. I can also provide an outline in the pattern by an absence of yarns or uncut pile to thus provide a most pleasing and novel efiect in the one piece of pile fabric.

Furthermore, the pile fabric may be made heavier to thus provide longer wearing qualities and the motifs formed by the two different methods will present a pleasing appearance during the entire life of the rug.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is:

1. A pile fabric comprising a conspicuous primary design motif, in combination with a more subtle secondary design motif, the primary design motif comprising areas of looped pile looped to a predetermined height together with areas of cut pile looped to a predetermined greater height. the areas of looped and cut pile bordering each other, the secondary design motif comprising lines of pile voids disposed in the areas of cut p le.

2. A fabric structure comprising a base fabric of woven warp and weft yarns and warp pile varns woven into the base fabric, the pile yarns forming a conspicuous primary design motif in combination with a more subtle secondary design motif on the face ofthe fabric. the primary design niotif comprising areas of looped pile looped to a predetermined height together with areas of cut pile looped to a predetermined greater height, the areas of looped and cut pile bordering each other, the secondary design motif comprising lines of pile-voids in the areas of cut pile with the pile yarns'of the voids confined in the base fabric. I l

3. A pile fabric comprising a conspicuous pri mary design motif in combination with a more subtle secondary design motif, the primary design motif comprising pile yarns of heavy weight forming areas of looped pile together with pile yarns of predetermined lighter weight forming areas of cut pile, the pile of the cut pile areas being looped to a predetermined greater height than the pile of the looped pile areas. the areas of cut pile and looped pile borderingeach other, the secondarv design ,motif comprising lines of pile voids in the areas of cut pile. i

4. A fabric structure comprising a base fabric of woven warp and weft yarns having at least four chains to the course and having a plurality of stuffer yarns and of pile yarns of different weights woven into the base fabric, the pile yarns forming a conspicuous primary design motif in combination with a more subtle secondary design motif on the face of the fabric, the primary design motif comprising the pile yarn of heavier weight formed in areas of looped pile looped to a predetermined height together with the pile yarn of lighter weightform'ed in areas of cut pile looped to a predetermined greater' height, the areas of looped pile and out pile bordering each other, the secondary design motif comprising lines of pilevoids in the areas of cut pile with the pile yarn of the voids confined in the base fabric.

5. A pile fabric design area woven unitary comprising a primary design characteristic and design characteristic comprising lines of pile voids aeronoe pedient comprising lines of pile voids'in' the cut pile areas of the first-mentioned design expedient, the pile voids in the cut pile areas and the areas of cut and unc'ut :pile being interrelated to provide the composite design of the design area.

7. A pile fabric design area comprising a plurality of fabric structures wovenunitary and cooperating to produce a composite design in relief, one fabric structure comprising juxtaposed uncut and cut pile areas providing a design configuration, the cut pile-being loopedto" a greater height than the uncut pile,"'an other fabric structure comprising pile voids in'the cut pile areas of the first-mentioned fabric structure, the areas of out disposed-in areas of cut pile, the pile voids of the pilecontairiing the pile voids,'and the areas of uncut pile being relatively'positioned to cooperate to producethecomposite design of the design area HAROLD H. BAYNTON. 

